ALSO: Preventing machine failures with effective bearing protection
How integrating Overall Equipment Effectiveness (OEE) and SQDIP boards can transform real-time data into actionable strategies and drive continuous improvement. 10 12 15 18 FEATURES
ELECTRIC MOTOR TROUBLESHOOTING
How to troubleshoot and maintain your motors to ensure optimal performance and prevent common failures.
MIND THE (SKILLS) GAP
As digital demands outpace workforce readiness, industry experts weigh in on the evolving skills landscape and what it will take for the industry to keep up.
PPE FOR YOUR SRB
Preventing costly machinery failures and reducing downtime with effective spherical bearing protection.
TURNING INSIGHTS INTO ACTION
Bridging the digital skills gap
I think I speak for most of us when I say that the future of industry depends not just on smarter machines but on people with the skills to use them. In this issue of MRO, we look at a growing challenge facing manufacturers across Canada: the widening digital skills gap.
Last fall, KnowMeQ released the results of a national skills assessment conducted through the NGen Future Ready program and the findings were sobering. Of the 900 employees tested across 115 Canadian manufacturing companies, many lacked the reading, numeracy and digital competency skills needed to meet the demands of modern industrial jobs. This aligns with broader research showing that while 90 per cent of jobs in Canada will require digital skills in the next decade, only 54 per cent of workers currently possess them.
I interviewed KnowMeQ founder and CEO Matt Foran shortly after the report came out. He emphasized that this isn’t just a training issue, it’s a productivity issue. When workers lack foundational skills, it limits their ability to take on more complex tasks and slows down innovation across the board.
Foran explained that many workers interact with technology only at a surface level—using digital tools without truly understanding how they work. This, he said, is no longer enough.
“We need to develop a skill level that can help us to still remain the agents of direction for the technology, not just trusting the technology completely,” he told me.
He also pointed out that digital competency is deeply connected to other foundational skills like literacy and numeracy.
“If you are not literate and then subsequently numerate, your
problem-solving skills will be lower, your critical thinking skills will be lower and your digital competency skills, of course, will be commensurate with that,” he said.
This issue’s cover story, “Mind the (Skills) Gap,” page 12, dives deeper into the implications of this growing divide. For this, writer Matt Jones spoke with experts across maintenance, manufacturing and workforce development to understand how organizations can respond through upskilling, smarter hiring and a renewed focus on adaptability.
On the topic of adaptability, Foran offered a note of optimism during our conversation
“I think that Canadian manufacturers and the manufacturing workforce are adaptable," he said. "A lot of the workers especially who have been in the workforce for many years have had new technologies come and go. In their own lives they’ve also had to adapt to different challenges and life experiences, that’s a positive.
“And I think that the idea, the definition basically of adaptability, is to be able to apply similar strengths and tools to new situations in times of uncertainty. And I think that that is a beacon of hope.You’ve got a really resilient workforce when it comes down to that.”
Perhaps with the right data, targeted support and a commitment to lifelong learning, the industry can bridge the skills gap. Because the future of maintenance and reliability isn’t just about machines, but the people who keep them running.
KIRSTYN BROWN Editor kbrown@annexbusinessmedia.com
ESTABLISHED 1985
SUMMER 2025 Volume 41, Issue 2
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FIRST OF FOUR SMRS TO BE BUILT AT DARLINGTON NUCLEAR SITE
The Ontario government has approved Ontario Power Generation’s (OPG) plan to construct the first of four small modular reactors (SMRs) at the Darlington nuclear site. This SMR will be the first of its kind in the G7, producing enough clean electricity to power 300,000 homes.
The construction of the four units will create up to 18,000 Canadian jobs and add $500 million annually to Ontario’s economy. The government also reports that the construction, operation and maintenance of the four units will add $38.5 billion to Canada’s GDP over the next 65 years and sustain 3,700 jobs. The government has ensured that 80 per cent of project spending goes to Ontario companies.
“This is a historic day for Canada as we start construction on the first small modular reactor in the G7, creating 18,000 jobs for Canadians,” said Stephen Lecce, Minister of Energy and Mines. “This nation-building project will be led by Canadian workers using Canadian materials to deliver reliable and clean power.”
The BWRX-300 reactor will use commercially available uranium to generate 1,200 megawatts (MW) of electricity, enough to power 1.2 million homes. Over 80 Ontario companies have signed agreements with OPG, and additional job commitments from GE Hitachi will be announced later.
ECONOMY
ONT. EXPANDS MFG. INVESTMENT TAX CREDIT
The Ontario government is expanding the Ontario Made Manufacturing Investment Tax Credit, providing an additional $1.3 billion over three years to help lower costs for businesses investing in buildings, machinery and equipment used for manufacturing or processing in Ontario.
“Manufacturing workers here in Ontario are already feeling the impact of President Trump’s tariffs, including job losses that are the direct result of the economic uncertainty he has caused,” said Peter Bethlenfalvy, Minister of Finance. “In response, our plan to protect Ontario will bring in new investments
to create new jobs and opportunities for our world-class manufacturing workers, so we can build a stronger economy capable of withstanding whatever comes our way.”
The proposed changes would increase the tax credit rate for Canadian-controlled private corporations from 10 per cent to 15 per cent and expand eligibility to non-Canadian-controlled private corporations. A qualifying corporation could receive a tax credit of up to $3 million per year.
INNOVATION
BAILEY ELECTRONICS BREAKS GROUND ON NEW B.C. FACILITY
Bailey International’s electronics division, formerly known as Sure Grip Controls, a provider of custom control solutions, has broken ground on its new facility in Victoria, B.C.
The project aims to bring the division’s operations under one roof, a move expected to improve efficiency and foster innovation in the heavy equipment industry. The new facility is scheduled for completion by
December 2026.
“This groundbreaking marks an exciting chapter for Bailey,” said Darren Lockyer, Vice President of Bailey’s electronics division. “This new facility represents our vision for the future. By ultimately uniting our teams under one roof, we will be better positioned to develop the customized control solutions our customers rely on.”
Bailey Electronics designs and manufactures custom controls for heavy equipment in agriculture, construction, forestry and transportation. The company uses lean manufacturing methods and emphasizes engineering to meet industry safety and performance standards.
ASSET MANAGEMENT
NANOPRECISE LAUNCHES AI TOOL FOR MAINTENANCE PROFESSIONALS
Nanoprecise Sci Corp. has announced the launch of ReKurv.ai, a generative AI solution designed to assist maintenance professionals in industrial environments.
The Darlington New Nuclear Project site, future home of North America’s first Small Modular Reactor.
Below: Bailey International breaks ground on new facility in Victoria, B.C.
Photos: OPG (top); Bailey International (bottom)
According to Nanoprecise, ReKurv.ai is a conversational intelligence tool tailored for asset management. It is trained on extensive machine hours and real-world use cases, aiming to provide answers to field technicians, reliability engineers, plant managers and executives.
“We built ReKurv for the people who keep the world running,” said Manpreet Singh, CTO at Nanoprecise. “When a motor starts vibrating erratically during a critical production hour, they don’t need assumptions, they need fast, real-time answers from something that understands how their machines actually work.”
Accessible via a mobile-friendly web app, ReKurv.ai reportedly offers machine-specific reasoning to maintenance teams. It interprets questions with plant-floor context, maps conversations to equipment hierarchies, retains historical threads and delivers responses from a curated knowledge base. The company says ReCurv combines generative AI with real-world equipment context and
aims to improve decision-making efficiency, reduce troubleshooting time and prevent downtime.
SUSTAINABILITY
DP WORLD PILOTS HYDROGEN FUEL CELL CRANE AT B.C. PORT
DP World has completed initial testing of its hydrogen fuel cell rubber-tired gantry (RTG) crane at the Port of Vancouver, aiming to decarbonize port operations. The RTG is now undergoing field testing to assess the feasibility of electrifying its global fleet of 1,500 RTG cranes.
DP World launched its pilot project in October 2023, retrofitting a diesel RTG with a Hydrogen-Electric Generator (HEG), battery energy storage system, hydrogen storage module, regenerative energy capture and integrated control and safety systems. The RTG is now in a one-year field trial to track performance parameters such as hydrogen consumption, energy generation, and regenerative energy capture rates.
DP World partnered with TYCROP Manufacturing Ltd., H2 Portable, and HTEC for this project. H2 Portable and TYCROP designed the HEG, while HTEC provided the hydrogen storage system and supply. The RTG crane stores up to 135 kg of compressed gaseous hydrogen in 15 pressurized tanks, feeding the fuel cell system that charges a high-voltage battery powering the crane’s electric drive. The bidirectional power system recovers energy when lowering containers, reducing energy demand and enhancing operational efficiency.
Above: Hydrogen fuelled rubber tired gantry crane at the Port of Vancouver.
Safety beyond the basics
Orientation isn’t enough—ongoing, tailored training is key to a safer workplace. Here’s how to build a program that protects workers, every day.
BY CANADIAN CENTRE FOR OCCUPATIONAL HEALTH
AND SAFETY (CCOHS)
When it comes to health and safety, employers have a responsibility to ensure that everyone has the training, tools and resources needed to work safely. This duty extends far beyond orientation at the start of a new job. Continuous training is a must.
According to a recent study by Threads of Life, a Canadian notfor-profit organization that supports families impacted by workplace tragedy, 49 per cent of employers cite a lack of time for training as the biggest challenge to improving the health and safety of their workplace. New workers who receive inadequate
safety training are significantly more likely to be injured on the job compared to their experienced colleagues, particularly in high-risk industries. However, ongoing training can help keep everyone in the workplace informed about evolving risks, new safety procedures and changes to the occupational health and safety legislation.
An effective training program should guide workers on how to recognize hazards, respond to emergencies, follow safe work practices to help to reduce the risk of incidents and injuries and understand the importance of reporting all unsafe acts, conditions and incidents.
Cover the relevant topics
The first step to build or improve a health and safety training program is to assess common hazards and risks to determine what kind of training is needed to reduce them. Every workplace is different, so tailor your training program accordingly. For example, review safety data sheets and equipment manufacturer’s instructions. It’s also important to talk to experienced workers and your health and safety representative or committee about what their challenges and experiences have been to gain insight into potential hazards. Another important step in the process is to review your safety logs and incident reports to gain insights into common injuries and near misses.
A few topics are universal: workers need to know how to identify hazards, assess risks, follow safe work procedures and use any required personal protective equipment correctly. Emergency preparedness is another critical area to include in your training. Everyone should know the fire safety, first aid and evacuation protocols in your workplace. For jobs that involve physical labour or repetitive tasks, providing education on proper ergonomics and manual and material handling techniques can help prevent musculoskeletal strains and injuries. Include specialized, industry-specific training on topics such as the proper operation and maintenance of tools and machinery, preventing slips, trips and falls with good housekeeping, safe storage practices and following prevention procedures such as lockout/tag out.
Also keep in mind that a truly safe workplace is one where psychological safety is prioritized alongside physical safety. Your training program should address problematic substance and mental health, stress management, harassment prevention and response procedures for workplace violence or harassment.
of employers cite a lack of time for training as the biggest challenge to improving the health and safety of their workplace, according to a recent study by Threads of Life.
Understand legislation in your jurisdiction
Consult provincial or federal safety agencies to make sure your training program meets the legal requirements for your industry and jurisdiction. The Canada Labour Code requires federally regulated workplaces to provide health and safety training and maintain hazard prevention programs, while provincial
organizations outline additional industry-specific requirements and risks. Failing to meet these standards can lead to legal consequences, financial penalties, and most importantly, preventable injuries. To avoid these risks, make sure your training program aligns with current regulations and best practices and are updated regularly to reflect any changes or updates.
Take advantage of technology
Technology can make it easier to provide effective and engaging health and safety training. Online learning allows workers to complete required courses at their own pace, making training more flexible and accessible. Virtual reality and digital simulations can create realistic training environments where workers can practice safety procedures without real-world risks. Mobile apps offer quick access to safety resources, hazard reporting tools and refresher courses. Data analytics can help employers track training completion rates, identify knowledge gaps and customize learning experiences based on individual needs. This personalized approach can help workers retain critical safety information and apply it effectively in their daily tasks.
Create a safety-focused culture
A workplace where everyone feels cared for and considered is a happier, healthier workplace. Encourage workers to speak up about safety concerns as soon as they arise. Demonstrate that all safety concerns will be
Workers need to know how to identify hazards, assess risks, follow safe work procedures and use any required personal protective equipment correctly.
taken seriously by having a process in place to record, investigate and follow up on them in a timely way.
Don’t forget to make use of the knowledge and expertise that already exists within your workforce. Consult experienced workers on your health and safety training program and get their feedback on any potential knowledge gaps. Introducing mentorship programs, where experienced workers guide newer employees through safety practices, can also be an effective way to get everyone involved and reinforce training in a practical setting.
A strong commitment to workers’ health, safety and well-being has benefits for the entire workplace. Deliver ongoing training, provide the tools and resources needed to work safely and foster a culture where conversations about incident prevention are encouraged.
The Canadian Centre for Occupational Health and Safety (CCOHS) promotes the total well-being — physical, psychosocial, and mental health — of workers in Canada by providing information, advice, education, and management systems and solutions that support the prevention of injury and illness. Visit www.ccohs.ca for more safety tips.
Electric motor troubleshooting
How to troubleshoot and maintain your motors to ensure optimal performance and prevent common failures.
BY L. “TEX” LEUGNER
Electric motors are essential to the operational success of industry. Unfortunately, most failures caused by excessive operating temperatures, stator winding deterioration, vibration, misalignment, improper lubrication of bearings, overloads and contamination could be prevented in their entirety.
1. Does the troubleshooter understand the motor manufacturer’s nameplate data?
LOGIC:The electric motor nameplate information provides the motor’s specific application data. For example, the nameplate information notes the “service factor” indicating how much over the rating any given electric motor can be driven without overheating.
2. Is the troubleshooter aware of the acceptable operating temperatures of the plant’s motors?
LOGIC :Excessive operating temperatures cause up to 40 per cent of electric motor failures and stator windings are temperature sensitive. Every 10⁰C rise in temperature above the specified insulation rating of the motor can reduce its life by as much as 50 per cent. The specified insulation rating is the sum of the ambient temperature, plus the maximum allowable operating temperature rise for that specific motor’s insulation class. The class F insulation rating of 155⁰C is common. Insulation ratings of A and B are lower, so care must be taken never to operate a motor beyond its insulation rating temperature as below.
Put in perspective, a motor operating at 180 degrees C will have an estimated life of: 300 hours with Class A insulation; 1,800 hours with Class B insulation; 8,500 hours with Class F insulation; and 10s of thousands of hours with Class H insulation. A “thermally protected” motor indicates
Manufacturer’s Name and Address
Catalog Number
Motor Model Number
Horsepower
Amps or FLA
Volts
Phase
HZ
Power Factor
RPM
Duty
Type
Motors often have a higher HP than is required. A motor that is too large will not give maximum efficiency and will have a poor power factor.
The current required at full load.
120, 208, 240, 277, 488, and 575 volts are common.
Single Phase or Three Phase and would state DC for Direct Current Motors.
Frequency in Cycles per Second.
Choose the motor with the highest power factor rating.
Shaft revolutions per Minute at Full Load.
Listed as Continuous, Intermittent, or Special Duty. Sometimes specified as 15, 30, or 60 Minute Duty.
Classification varies depending on manufacturer
Code Indicates Locked Rotor KVA per Horsepower.
Enclosure
Service Factor
NEMA Electrical Design
Frame Number
Max Ambient
Insulation Class
Open, Totally Enclosed, Drip-Proof, Splash-Proof, Weather Protected, Explosion-Proof are the options.
Measure of continuous overload capacity.
The design letter represents the Torque Characteristics. B, C, and D.
Frame number indicates external dimensions, horsepower, and speed.
Usually +40⁰C (104⁰F).
Normally specified as class A, B, F, or H.
Typical nameplate data
that a thermal protection device is part of the motor and will protect it from overheating as noted below.
3. Is the troubleshooter aware that any operating temperature higher than normal is an indication of a potential failure?
LOGIC:Higher than normal operating temperatures are always the sign of a problem, including loose, worn or corroded connections, unbalanced loads, harmonics, poor contacts, stator winding deterioration, shorted windings, incorrect line voltage, or phase imbalance. Causes of high temperatures include blocked ventilation, restricted cooling fans, excessive dirt or dust on the motor housing, and over-greasing of bearings causing increased bearing temperatures.
4. Is the troubleshooter aware of all potential causes of motor failure?
LOGIC: Electric motors do not fail without a cause. The failures noted earlier can be prevented by routine testing thus improving the reliability of motors. Almost all motor electrical failures are the result of some form of insulation or rotor component deterioration, and a common cause of winding insulation damage is an accumulation of dirt and dust that can abrade insulation and prevent proper cooling.
Excessive moisture reduces the dielectric strength of insulation that can
result in short circuits. Oil and grease accumulations inside the motor will increase operating temperatures damaging winding insulation.
5. Is the troubleshooter aware of the electrical tests that will provide the condition of winding insulation?
LOGIC:The following condition monitoring electrical tests should be part of the troubleshooter’s toolkit:
• The Ground Insulation or “Megger”Test, used to apply DC voltage, to measure the insulation resistance.
• The Surge Test measures the turn insulation in form wound or random wound stator windings.
• The Partial Discharge Test, to locate electrical sparks that can occur in stator windings at 4 kV or higher. In poorly manufactured motors with deteriorated windings due to overheating or contamination, then partial discharges will occur.
• Current Signature Analysis analyzes the current on a single power cable feeding the motor to monitor its frequency. Specific frequencies in that current indicate the presence of defective rotor windings during the motor’s normal operation locating cracked rotor bars, bars with large internal voids created during manufacture, broken barto-short circuit ring connections, or cracked short circuit rings.
6. Is the troubleshooter aware of the potential problems that harmonics can cause in motors?
LOGIC: The fundamental frequency (usually 60 Hz) is the predominant intended frequency of a power system. Harmonics are identified by
their number. In a system with a 60 Hz fundamental frequency, 120 Hz is the second harmonic, 180 Hz the third harmonic, 300 Hz the fifth, and so on.
Harmonic distortions of the fundamental frequency are caused by non-linear loads such as the switched mode power supply used in variable speed drives and personal computers creating problems in electrical equipment that can be difficult to diagnose. If harmonics problems are suspected in any electrical system, measure the load current with an average reading ammeter, then with a true RMS reading ammeter and compare the difference. If harmonics are present, the average reading instrument will read lower than the RMS instrument.
7. Does the troubleshooter understand excessive operating temperatures can affect bearings and motor efficiency?
LOGIC:Temperature-related problems can seriously affect bearing life in electric motors regardless of whether they are grease or oil lubricated. In addition to excessive temperatures, contamination, belt misalignment or adjustment, rotor imbalance, coupling misalignment, moisture, electrical discharge (through the bearing), and incorrect oil viscosity (whether in the grease or the oil itself), can all affect bearing life and motor reliability.
L. (Tex) Leugner, author of Practical handbook of Machinery Lubrication, is a 15-year veteran of the Royal Canadian Electrical Mechanical Engineers, where he served as a technical specialist. He was the founder and operations manager of Maintenance Technology International Inc. for 30 years. Tex holds an STLE lubricant specialist certification and is a millwright and heavy-duty mechanic. Ask him your questions at lloydleugner@gmail.com.
The Ground Insulation Test, or "Megger Test," should be part of a troubleshooter's toolkit.
Mind the (skills) gap
As digital demands outpace workforce readiness, experts across maintenance, manuacturing and workforce development weigh in on the evolving skills landscape and what it will take for the industry to keep up.
BY MATT JONES
In September 2024, KnowMeQ, a provider of science-validated assessments and AI tools for workplace upskilling, released the results of a skills assessment it had conducted as part of the Next Generation Manufacturing Canada (NGen) Future Ready program. The assessment—an online test that measured various competencies of 900 employees from 115 manufacturing companies—determined that the Canadian manufacturing workforce, overall, lacks the reading, numeracy and digital competency skills needed to meet the demands of jobs in modern, industrialized economies.
“This [lack of skills] contributes to our productivity challenges,” says KnowMeQ founder and
CEO Matt Foran. “We have seen very consistently, and it’s been documented in different research, that individuals in work settings in Canada, about 50 per cent of them don’t have a level of skills to meet the core demands of the jobs. And that becomes a real impediment to that body of workers’ ability to take on greater, more complex tasks and weighs down the opportunities for greater efficiencies in productivity.”
September also saw the release of a report titled Building a Digitally skilled Workforce by the Conference Board of Canada, which estimated that while over the next decade 9 of 10 jobs in Canada would require digital skills, only 54 per cent of workers possessed them. Furthermore, a 2022 national survey conducted by
Salesforce determined that 81 per cent of respondents said they don’t feel equipped to learn the digital skills needed by businesses today.
MRO spoke with experts across manufacturing, maintenance and workforce development to gain deeper insights into these findings and what they mean for the current state of the industry and beyond.
A workforce behind the curve
Heather McIntosh, Director of Education and Skills at the Conference Board of Canada, says the digital skills gap is partially due to the fast-evolving landscape of digital tools and technologies that are now accessible to industry professionals.
“The challenge is the pace at which these new tools become available is
“Sector by sector, there’s going to be nuances in terms of how digital skills change… there’s going to be a lot of integration with AI platforms and interfaces. So having a strong background and understanding of how to use computers would help in that way.”
– Vivian Li, senior economist, the Dais, TMU
quite rapid,” she says. “You compare that with the existing labour force, and many of the folks who would be in occupations like maintenance and repair and asset management often are older and more mature in terms of their demographics. These folks would not have been trained during an era in which smartphones are being used to track hours or to service a tool.”
David Mason, Director of Reliability, Maintenance & Turnaround at Nova Chemicals, describes the state of digital skills in the sector as developing. He notes that harmonizing technology and terminology has benefitted NOVA and could benefit wider sectors. Mason compares this to the standardization of cell phone chargers to USB-C, which took years to achieve.
“It’s going to be similar in digitalization,” says Mason. “It’s going to take time because it’s such a fledgling market. You see so many new entrants, little niche
technologies, and as some of the big players come in they start to standardize. Eventually, we’ll get to a place where it’s much more standardized. But it’s going to take 20 to 30 years, I think.”
Mason’s colleague, Ahmed Musa, Leader of Digital Manufacturing and Digital Transformation at Nova, says that this will be a continuing conversation as new digital skills become increasingly required in the market.
“Digital skill set is just another tool,” says Musa. “50 years ago, there was no Microsoft, no SAP, no CMMS— everything was on paperwork. Now when you go to the [labour] pool, you’re not going to look for someone who has zero computer skills in the maintenance world. They need to be equipped with at least some of the basics. Now that baseline will go a bit higher with the existing tools in the future and that’ll be the requirement.”
Evolving roles, evolving tools
Vivian Li, a senior economist at the Dais, a think tank at Toronto Metropolitan University, emphasizes the importance of the wider industry keeping abreast of which digital skills are necessary and how they may be specialized by sector. Li notes that while emerging trends such as AI get much of the focus, the most in-demand digital skills are as simple as being able to work with Microsoft Office Excel and other digital office tools. However, she acknowledges that this may change in the future.
“Sector by sector, there’s going to be nuances in terms of how digital skills change,” says Li. “We’re expecting that there’s going to be a lot of integration with AI platforms and interfaces. So having a strong background and understanding of how to use computers would help in that way.”
Mehboob Karim, Chief Technical Advisor of Digital Transformation and Operational Excellence for Ontario’s Institute of Business Management, has witnessed the evolution of digital skills throughout his career, which began in the 1990s in asset management services. Karim highlights the significant impact of AI on the workforce.
“People are smart, but the machines are getting even smarter these days because of AI,” says Karim, who says true transformation within an organization requires a total cultural shift. “It’s a way of thinking because transformation includes all technologies. That’s where we differentiate between digital technology and digital transformation,” he explains.
While Karim acknowledges that a complete transformation is still a work in progress, he sees promising advancements in maintenance. “I know we are not there yet, at a complete transformation, but maintenance is getting there,” he says. “We’re talking about smart maintenance, wireless IoT sensors on machines—the whole idea is to have critical assets in real time sending information and predicting breakdowns.”
Upskilling as a strategy
To address the digital skills gap, Karim emphasizes the importance and value of organizations that offer opportunities for upskilling. Karim cites maintenance management and asset management certificates offered by PEMAC Asset Management Association of Canada as a good example.
PEMAC Executive Director Cindy Snedden says that their recent conferences have focused on blockchain technology, AI and machine learning. She says they are careful to include experts who are developing and commercializing those technologies along with practitioners who are implementing them in the field.
“From the outset PEMAC educational programs have been designed to centre basic principles and strategies, situating all technological tools as just that—tools that are best leveraged when certain fundamentals are in
FUTURE READY FAST FACTS
In 2023 to April 30, 2024, NGen’s Future Ready program brought together organizations representing the aerospace, automotive, biomanufacturing, heavy industry/ mining equipment, food manufacturing and shipbuilding sectors to do cross-sectoral research into the core skills needed by the Canadian manufacturing workforce today through 2040. The program also:
• Delivered over $900,000 in upskilling training grants to manufacturers
Registered over 400 companies for online skills assessments
Ran over 700 workers through a Transformation Leadership Program
Developed 42 tools aimed at upskilling.
place,” says Snedden. “This is an approach that has proven effective and equips professionals to assist their organization in deciding which tools and technologies are timely for the organization and its needs.”
A report by the Conference Board of Canada estimates that while 90 per cent of jobs in Canada will require digital skills over the next decade, only 54 per cent of workers currently possess them.
Asked what Canada should do in response to the knowledge and skills gaps, Karim says that funding for the National Research Council of Canada’s Industrial Research Assistance Program (IRAP) should be increased in order to support innovation and R&D among SMEs.
“If we can encourage our medium-sized and small businesses to do some more research and come up with their own products, IRAP is in an excellent position to do that,” says Karim, suggesting that as these companies adopt new technologies through IRAP-supported projects, their employees will need to upskill to use these technologies effectively.
“You just need to increase our funding. They help people foster innovation and they help small businesses to grow by providing financial assistance in the form of grants.”
McIntosh agrees and highlights the importance of individual companies in this process. She has observed that the best outcomes occur when companies take initiative by either offering their own training or partnering with educational institutions to influence content development. While not all companies can implement their own training programs, collaboration remains valuable.
“I am not saying it’s a one-size fits all approach, but we do know that when employers step up, they have insight and they are driven to grow and be cash positive,” says McIntosh. “Getting their buy in on what needs to happen is so critical because they know best.”
“The biggest thing that we have to help people understand is that we have to keep up with the pace of change,” adds Mason. “If we as human beings, if we as workers, want to remain relevant, then we have to jump on board.”
PPE for your SRB Preventing costly machinery failures with effective bearing protection.
BY WYATT PHILLIPS
Anyone who has experienced sand in their eyes knows that even the tiniest abrasive particle can significantly irritate and damage a precision instrument. It's common sense to wear sealed goggles if our work environment has highly abrasive dust and contaminants. And just as we protect our eyes, we must shield our machinery from contamination to prevent costly damage and downtime.
Common failures do not have to be common
Precision machinery, such as bearings, requires clean, controlled operating conditions to function correctly. Spherical roller bearings (SRBs) are one of the industry’s most widely used bearings due to their versatile features, such as heavy radial and axial load ratings and their ability to auto-compensate for misalignment. These attributes
make SRBs a highly popular choice for installation in the harshest applications. They are often installed on high-load conveyors in remote or difficult-to-maintain locations where contamination risks are severe.
Unfortunately, many operations experience premature failures in these challenging applications due to inadequate bearing protection (Figure 1). Consequently, some facilities have become accustomed to replacing their SRBs after just weeks of service.
The consequences of inadequate protection
Consider the example of a gold mine that experienced frequent bearing failures on its conveyors. In a reliability meeting, the maintenance team shared an image of a failed SRB assembly with me. Mounted on a large mine-duty conveyor pulley, the bearing was glowing red-hot as it ground
through the side of the cast housing, with pieces of hot slag falling to the ground below. The conveyor pulley had been installed for only a few weeks. Our inspection revealed that the primary cause of failures was heavy contamination.
These bearing failures were an ongoing headache for the mine. Replacing a bearing was a five-hour job, resulting in considerable production losses, hazardous conditions and an extremely high volume of replacement bearing purchases.
The most common cause of bearing failure
While your operation may not experience SRBs melting, failures may still be a familiar problem. Most SRBs never reach their expected life. One leading bearing manufacturer reports that 51 per cent of bearing failures are due to contamination
and ineffective lubrication.
Tiny particles from windblown dust or spilled fugitive materials can enter a bearing. Once inside, they mix with the lubricant to form a grinding medium, wearing down the bearing components. Larger abrasive particles can create indentations on the bearing’s rolling surfaces, resulting in failure.
Water is another contaminant that can corrode bearing surfaces and degrade the lubricant. Bearings stored without temperature controls can suffer from condensation, and even 1 per cent of water in the lubrication can be detrimental. Additionally, pressure-washing equipment can force solid particles and water through the bearing housing seals and into the bearings, causing damage.
SRBs lacking adequate protection will prematurely fail—and these failures will not wait for conveniently scheduled maintenance shutdowns. Contamination remains a constant threat, but effective strategies exist to safeguard your SRBs and enhance uptime.
PPE OPTIONS FOR YOUR SRB
Taconite seals
Most common bearing housings can be fitted with various seal options. Installing taconite seals will significantly improve bearing reliability in industries facing extreme contamination risks. These seals were named after their development 60 years ago for the iron industry, which produced
a bearing-killing, fine-grained, abrasive taconite ore.
A quality taconite seal features a compact, multistage cartridge design, typically consisting of two labyrinth rings: one that rotates and one that remains stationary. Between the two rings, a narrow labyrinth prevents contaminant ingress, even during high-pressure washdowns. The rotating ring
has a V-ring seal that seals off the stationary ring, stopping materials from entering the housing while facilitating the purging of contaminants when new grease is injected.
Integrally sealed bearings
One of the most common installations for SRBs is in split pillow block assemblies, which are valued for ease of installation and maintenance (Figure 2). However, this benefit comes with a liability: An open-bearing assembly potentially risks contamination during installation. Even the best taconite seals cannot protect against contaminants introduced directly into the housing during assembly.
Assembly in a clean, controlled environment is not always feasible in the real world. Occasionally, bearings must be installed in an environment that exposes the internal components to weather, windblown dust and debris, guaranteeing contamination. You can mitigate even these contamination risks by upgrading your bearing selection.
Sealed SRBs provide robust protection against bearing contamination of all kinds. These bearings come pre-lubricated with specially formulated grease and are factory-equipped with high-performance contact seals.
Research indicates that sealed spherical
Figure 2. This split housing pillow block bearing assembly is being disassembled for bearing replacement. If a new bearing cannot be installed in a clean shop environment like this, opting for a sealed SRB can help prevent contamination during assembly.
Figure 1. This SRB from a coal mine failed due to fugitive material contamination. The standard-duty bearing lip seals were not properly selected for this application.
bearings can deliver three times longer service life than standard open SRBs. However, the extended lifespan is not the only advantage. Since the bearing is sealed with its own grease, there is no need for constant re-lubrication to purge contaminants. This results in less grease consumption and fewer maintenance hours in potentially hazardous areas.
The triple protection solution
What if we combined the barriers discussed above into a single assembly? Using this combination of defenses, contaminants would have to penetrate through a taconite-duty labyrinth seal, a grease-filled cavity and the bearing seals (Figure 3). That is significant protection.
To set up this ultimate triple protection barrier, start with taconite-duty seals, which have their own grease fitting. This allows the purging of contaminants in the old grease during re-lubrication.
Next, housing grease needs to be addressed. The recommended amount of grease for a bearing housing depends on factors like speed and temperature. However, many conveyor applications allow for grease to fill up to 75 per cent of the housing capacity, effectively serving as a secondary barrier. Remember, in this triple protection setup, the cavity grease functions solely as a barrier and does not directly contact the bearing rollers.
The final line of defense is the
Figure 3. This pillow block-bearing assembly has three defensive barriers against contamination: a taconite seal, housing cavity grease (biodegradable) and an SRB with its own integral seals.
integrally sealed bearing, which comes pre-filled with grease and fitted with seals out of the box. Aside from proper installation, there is little to worry about.
We installed a bearing assembly with these three barriers on the most problematic conveyor at the gold mine mentioned earlier. The results have transformed their maintenance and reliability expectations.
• Failures have ceased, eliminating unscheduled maintenance.
• Re-greasing frequency has decreased from weekly to only twice annually, saving up to 88per cent of the time and cost of re-lubricating.
• Maintenance employees no longer face regular, dirty and risky bearing changes in the middle of the night.
Contact your bearing distributor for assistance selecting the proper protection for your application. SRB PPE: It’s not complicated, but it works.
Wyatt Phillips is Motion’s Prince George branch manager in British Columbia. A technical account representative for 10 years before his last five as branch manager, Phillips currently leads a team focused on developing reliability-centered solutions for customers in BC’s growing mining industry. For more information, visit Motion.com.
Turning insights into action
How integrating Overall Equipment Effectiveness (OEE) and SQDIP boards can transform real-time data into actionable strategies and drive continuous improvement.
BY ELI LATAK
Facing the relentless push for efficiency, manufacturing organizations are under growing pressure to optimize performance, reduce costs and deliver consistently high-quality products. To meet these expectations, leading manufacturers are leveraging Overall Equipment Effectiveness (OEE) in conjunction with structured management tools like Safety, Quality, Delivery, Inventory and Productivity (SQDIP) boards. Together, these systems enable teams to monitor performance, drive continuous improvement and foster a culture of accountability and transparency across all levels of the organization.
What is OEE?
OEE is a gold-standard metric used to assess how effectively a manufacturing operation is utilized. It is a composite metric made up of three key components:
• Availability – Measures downtime losses.
• Performance – Measures speed losses.
• Quality – Measures defect losses.
A perfect OEE score of 100 per cent indicates that a machine produces only good parts, as fast as possible, with no downtime. While this is rarely achievable, the goal of using OEE is not perfection but the identification and elimination of losses. Based on our extensive work with customers and their data, the reality is that most manufacturing organizations’ OEE scores are closer to 50 to 60 per cent, depending on how long they have been tracking OEE. So, while a world-class OEE score of 85 per cent and above is extremely desirable, most manufacturers are unlikely to achieve such results. That’s why companies should not focus on striving for 85 per cent as a minimum but rather set their sights on raising their OEE through specific improvements.
Now that you’ve started collecting
OEE data, what are you doing with it? How should it be managed? Our recommendation is to use daily huddles with SQDIP management boards.
What is SQDIP?
SQDIP stands for Safety, Quality, Delivery, Inventory and Productivity. It is a structured, visual management system that aligns daily activities with strategic goals. SQDIP boards are commonly used in tiered management meetings to monitor key metrics and encourage real-time decision-making. Each letter in SQDIP represents a core pillar of operational performance:
• Safety – Ensures a safe working environment and tracks incidents.
• Quality – Measures defects, rework, and process capability.
• Delivery – Tracks on-time delivery and schedule adherence.
• Inventory – Monitors raw material and finished goods levels.
• Productivity – Measures efficiency through KPIs like OEE.
S.Q.D.I.P Managing Boards
A perfect OEE score of 100 percent indicates that a machine produces only good parts, as fast as possible, with no downtime.
By combining OEE with SQDIP boards, companies can create a closed-loop system of performance monitoring and improvement.
Benefits of integrating OEE with SQDIP boards
1.Real-Time Visibility of Performance. One of the greatest strengths of using SQDIP boards in conjunction with OEE is realtime visibility. Teams can quickly identify underperforming areas by visually displaying OEE metrics and performance indicators under the Productivity section. With real-time data available during daily meetings, teams can:
• Identify trends or recurring issues.
• Make immediate decisions and take corrective actions.
• Maintain alignment across shifts and departments.
2. Structured Problem Solving. SQDIP boards encourage root cause analysis and structured problemsolving. When an issue is identified— such as a dip in OEE due to machine downtime—it is logged on the board. Teams are then encouraged to use tools such as 5 Whys or Fishbone Diagrams to identify and eliminate root causes.
This systematic approach to problem resolution ensures issues are not only fixed but prevented from recurring.
3. Improved Communication and Accountability. Daily tiered huddles centered around SQDIP boards create a culture of open communication. Each department or cell presents their performance, including OEE data,
and outlines actions taken to address any deviations. This transparency:
• Encourages team ownership of problems.
• Fosters collaboration across departments.
• Build a consistent feedback loop.
Managers can quickly understand what’s working and where support is needed.
4. Focus on Leading Indicators. While traditional KPIs often focus on lagging indicators (like monthly output), SQDIP and OEE emphasize leading indicators.These provide early warning signs of potential problems. For example:
• A drop in performance (OEE) on a single line may predict late delivery (D in SQDIP).
• Increases in changeover time or minor stoppages can indicate future quality or availability issues.
By catching these signals early, teams can proactively prevent bigger issues downstream.
5. Drives Daily Continuous Improvement (Kaizen). One of Lean manufacturing’s core tenets is Kaizen—continuous, incremental improvement. SQDIP boards support this philosophy by identifying improvement opportunities every day. Examples include:
• Standardizing work to reduce performance losses.
• Implementing quick changeover techniques to boost availability.
• Using OEE loss trees to guide Kaizen events.
By reviewing daily metrics and tracking actions on SQDIP boards, improvements become habitual rather than sporadic.
6. Alignment of People, Processes, and Purpose. Visual boards provide a common language that aligns crossfunctional teams. Whether you’re an operator, supervisor, or plant manager, SQDIP provides clarity on what matters.
Coupled with OEE data:
• Operators understand how their actions impact productivity.
• Maintenance teams prioritize based on high-impact issues.
• Leadership makes decisions based on real performance data.
This alignment ensures that everyone is working toward the same goals and using the same data to get there.
7. Enhanced Standardization and Documentation. Using OEE within a visual management system promotes consistency. Over time, best practices are documented and shared, creating a standardized approach to improvement. These include:
• Documented standards for changeovers.
• Maintenance checklists to improve equipment availability.
• SOPs for addressing quality issues.
As standards evolve, the SQDIP board becomes a living document of the organization’s best practices.
8. Motivation and Team Engagement. Seeing performance metrics like OEE displayed on SQDIP boards provides immediate feedback. Teams know where they stand and what they need to improve.
When targets are met, it builds confidence. When they aren’t, it sparks problem-solving.
This daily rhythm of review and action boosts morale, encourages team ownership, and embeds a culture of excellence.
OEE and SQDIP boards are more than just tools, they are cultural enablers. Together, they empower teams with real-time data, visual feedback and a structured problemsolving approach. This combination enhances communication, accountability and alignment, ultimately driving sustained improvements in productivity, quality and safety.
Organizations that integrate OEE within the SQDIP framework are better equipped to face the challenges of modern manufacturing. By focusing on what matters every day and acting on it, they build a resilient, high-performing operation ready to compete and thrive.
Eli Latak, MBB, is the founder of Smart Lean Manufacturing, a hands-on operational excellence implementation service.
WHAT’S NEW IN PRODUCTS
ROBOCLIP™ BY INNOVATIVE AUTOMATION
Innovative Automation Inc. has unveil RoboClip™, a system engineered to automate the precise, repeatable placement of clips in high-performance manufacturing environments.
RoboClip is the latest addition to Innovative Automation’s portfolio of advanced production technologies. It attempts to address a bottleneck in clip-based assemblies, offering manufacturers an alternative to custom automation.
With a fully integrated robotic platform, RoboClip aims to ensure consistent clip positioning across a wide range of part sizes and
geometries. Innovative Automation says the system comes with an intuitive user interface to make teaching points quick for operators or maintenance.
RoboClip is suited for automotive, appliance and industrial applications, where consistent clip fastening is critical to structural integrity and assembly quality. www.roboclip.com
ENDRESS+HAUSER DOSIMAG AND DOSIMASS FLOWMETERS
Endress+Hauser has launched the next generation of its Dosimag and Dosimass flowmeters, now
available with IO-Link connectivity—a first for this class of filling instruments. Designed for high-precision liquid measurement in filling and batching applications, the updated models offer enhanced digital integration, faster commissioning, and real-time diagnostics. The IO-Link versions support seamless migration from existing systems and aim to improve operational efficiency across sectors such as food and beverage, pharmaceuticals, and chemicals. www.ca.endress.com
GrayWolf Sensing Solutions has released the DirectSense® XM, a modular smart probe and datalogger designed for indoor air quality, HVAC validation, and industrial hygiene monitoring. The unit supports 2 to 8 interchangeable plug-and-play sensors, with over 25
sensor options available— including TVOCs, CO₂, formaldehyde, and various toxic gases. It features onboard data logging capable of storing months of readings, and offers connectivity via Bluetooth LE, Wi-Fi, and USB. The DirectSense XM is compatible with GrayWolf’s AdvancedSense® XM meters and integrates with Windows, Android, iOS, and MacOS platforms. It also supports cloud-based logging through the GrayWolfLive™ app. Designed for both handheld and wall-mounted use, the device
The World of Bearings and Power Transmission...
includes built-in fans for faster response times, a rugged enclosure, and a rechargeable Li-ion battery. Its smart sensor design allows for calibration data to travel with each sensor, simplifying maintenance and replacement. www.graywolfsensing.com
Emerson has introduced the Rosemount™ 490A, a digital optical dissolved oxygen sensor designed to reduce maintenance and enhance integration across industrial applications. Featuring
Modbus RTU communication, the sensor supports seamless connectivity with a wide range of control systems. It delivers accurate measurements in both liquid and gas phases, with a fast 90-second response time and no need for water flow or electrolyte refills. The IP68-rated design, two-year sensing cap lifespan, and EPA-approved luminescencequenching technology make it well-suited for demanding environments such as water treatment, power generation, and food and beverage processing. www.emerson.com
API ILT: 6TH GENERATION INTEGRATED LASER TRACKER
Automated Precision Inc. (API) has introduced the iLT, its sixthgeneration laser tracker, designed for enhanced portability and ease of use in precision measurement applications. Weighing just 4.9 kg,
the iLT features hot-swappable batteries, onboard control, and Wi-Fi connectivity for fully cableless operation. It includes an upgraded 8MP camera with iVision™ autolock, an AI-enhanced GPU for faster data processing, and a compact, rugged design. Available in two models, the iLT and iLTx, the system supports a range of industrial applications including equipment alignment, modular construction, and field-based inspection. www.apimetrology.com
PIAB PICLASSIC™ NEO
piCLASSIC™ Neo is Piab’s latest evolution of its trusted vacuum pump, designed for modern industrial needs. It features a new multi-stage COAX® ejector for improved efficiency and adaptability, with two variants for flexible installation, including robotic and EOAT setups. Quick to install and easy to maintain, it supports reduced downtime and long-term reliability. With energysaving functions and sustainable materials, it cuts CO₂ emissions by up to 58%, offering a smart, future-ready solution for efficient and eco-conscious manufacturing. www.need website.com
Grease under pressure
Exploring the hidden limits of grease lubrication in high-speed, high-load bearing applications and how to avoid costly missteps.
BY DOUG MARTIN
Grease is the most commonly used lubricant for rolling element bearings in industrial applications, and for good reason. It enables simpler, more cost-effective machine designs. Because of this, manufacturers often push the limits of grease lubrication.
Unfortunately, those limits aren’t always well understood by users or even some designers.
Over the past 30 years, the understanding of grease speed limitations has evolved. What was once a simple maximum speed guideline has become more nuanced with the introduction of the reference speed concept.
In the 1990s, bearing manufacturers began publishing a “reference speed” for bearings. The reference speed was a value that was intended to be used in calculations that account for bearing type and load conditions. The result is the adjusted limiting speed, which indicates the maximum speed before active heat removal (typically via oil circulation) becomes necessary. Initially, these were manual calculations, but in the past decade, bearing manufacturers have integrated them into online tools and selection software. Users now input basic data—bearing type, loads, and speed—and receive adjusted speed values along with warnings about grease suitability.
Despite these tools and catalog explanations, the idea that grease has speed limits still isn’t universally understood. To determine whether grease is appropriate for a given application, users need to know:
• Bearing size
• Bearing type
• Operating speed
• Applied radial load
• Applied axial load
The first step is to calculate the bearing mean diameter (dm), which is the average of the bearing bore and bearing outside diameter. Then this value is multiplied by the bearing
speed (n), in rpm to determine the value ndm.
For ball bearings, this ndm value, along with the load ratio (bearing dynamic capacity divided by equivalent applied load), helps estimate the maximum grease-appropriate speed. This is an approximation, not a hard limit. Some software will flag applications operating within 70 per cent of this threshold, indicating that grease may not be suitable. As with most heat transfer calculations, the number of variables makes precise limits impractical.
For cylindrical roller bearings (CRBs) and self-aligning roller bearings, such as spherical roller bearings (SRBs) and CARB, the internal geometry significantly affects heat generation. In CRBs, the number of lips on the inner and outer rings influences speed capability. In SRBs, the ratio of axial to radial load is critical.
Axial load is the key factor in both cases. It generates heat either through roller end contact with ring lips in CRBs or by fully loading one roller path in SRBs. In CRBs, it’s
about sliding contact. In SRBs, if the axial-to-radial load ratio exceeds the geometry factor “e,” only one roller path carries the load, increasing heat and reducing grease life.
I recently reviewed an application with a high axial-to-radial load ratio. The speed was too high for grease, but increasing the radial load would have made grease viable. While higher radial loads can also generate heat, they tend to have a lesser impact than axial loads.
In summary, grease is a convenient and widely used lubricant, but it has real limitations. Always consult online bearing selection tools and catalog data when evaluating grease suitability. If your application speed is within 30 per cent of the published reference speed, take a closer look— you might be pushing grease beyond its limits.
Douglas Martin is a heavy-duty machinery engineer based in Vancouver. He specializes in the design of rotating equipment, failure analysis and lubrication. Reach him at mro. whats.up.doug@gmail.com.
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